Configurable welding interface for automated welding applications

ABSTRACT

A welding power source including an embedded web server provides access to an operator at a remote web browser. From the remote web browser, the user is provided access to weld functions, and can selectively choose between weld functions that can be displayed and controlled from the remote web browser. The weld functions that can be accessed include control functions, which allow an operator to activate welding functions such as a jog or purge function; a command function, which allows an operator to provide a command level for a voltage, wire feed speed, or other parameter; and a display function, which provides access for an operator to display welding command and actual feedback values. The operator can also selectively view diagnostic data, including weld state data, error data, and operational voltage and current levels within the power source, such as motor voltage and input voltage levels. After an operator selects parameters to be displayed or controlled from the browser, the selected functions can be stored and recalled as a web page.

FIELD OF THE INVENTION

The present invention is directed to a method and apparatus forconfiguring welding operations.

BACKGROUND OF THE INVENTION

As the level of automation has increased in mass production facilities,and the speed of welding operations has increased, it has becomeincreasingly important for management personnel to monitor and controlwelding parameters, processes, and weld cell set-up parameters in afacility. Proper monitoring and control helps to ensure consistent andproper joining of materials, to ensure that completed welds fall withinpredetermined quality parameters, and to ensure that material waste andoperational downtime is avoided.

The need for improved monitoring, moreover, has increased in recentyears as welding personnel on the factory floor are frequentlyinexperienced in welding operations. Often, operators are minimallytrained, and cannot properly choose weld parameters, or identify andcorrect for problems encountered during welding processes and weldset-up. Therefore, it is also important for management personnel tomonitor weld and operator performance, and to quickly identify problemoperators and areas.

As a result, there are differing levels of monitoring requirements inmost facilities. Operators are typically interested only in monitoringvery basic command and readout parameters, and in having access to verybasic controls. Supervisory personnel, however, need to access largenumbers of control parameters, feedback parameters, and weld set-upparameters to properly monitor, control, and troubleshoot weldingproblems. Moreover, it is important for supervisory personnel to be ableto choose the types of data monitored, in order to evaluate and focus inon parameters that might be outside of an appropriate range, or thatmight provide a basis for analyzing problems in a weld. Monitoringselected controls and parameters simplifies the process for managementpersonnel to analyze the welding process, identify problems, and makecorrections before significant down time or waste of material occurs.

Additionally, when problems are encountered with equipment in a weldcell, or with consumables in the cell, it is important for managementpersonnel to identify these failures and to make correction andreplacements easily. In an automated environment, it is particularlyimportant to be able to replace a piece of equipment from a cell with analternative component providing the same feature, and to troubleshootthe removed piece of equipment offline. In these situations, it isimportant to minimize the amount of time required to set up the systemfor the alternative component, and to provide a “plug and play” solutionto limit downtime. The present invention addresses these issues.

SUMMARY OF THE INVENTION

In one aspect of the invention, a welding power source is provided. Thepower source includes a power supply, a controller coupled to the powersupply to provide weld parameter control signals to the power supply,and an embedded web server in communication with the controller and aremote client browser. The web server is programmed to allow a useraccessing the remote client browser to select between a plurality offunctions for displaying and controlling weld parameters of the weldingpower supply, to provide a customized operator interface at the remoteclient browser for monitoring and controlling the power supply. Theuser, therefore, can selectively control and display weld parameters atthe remote client browser.

In another aspect of the invention, a method for providing acustomizable remote interface for a welding power source and associatedwire feed system having an embedded web server is provided. In thismethod, an embedded web server is communicatively coupled to acontroller of the welding power source. The server is programmed toprovide selective access to weld functions that provide at least one ofa display, a control, and a command function of the welding system froma remote browser. Access to the embedded server is provided from theremote web browser, wherein an operator at the remote web browser canselectively choose among the weld functions to customize an interface todisplay, control and command weld functions from the remote browser. Thecustomized remote interface can then be stored for recall.

These and other aspects of the invention will become apparent from thefollowing description. In the description, reference is made to theaccompanying drawings which form a part hereof, and in which there isshown a preferred embodiment of the invention. Such embodiment does notnecessarily represent the full scope of the invention and reference ismade therefore, to the claims herein for interpreting the scope of theinvention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a block diagram of a welding system capable of use in thepresent invention;

FIG. 2 is a simplified block diagram of the embedded web server in thewelding system of FIG. 1, illustrating data storage and flow between anembedded web browser and a remote web browser;

FIG. 3 is screen shot illustrating a web interface login screen foraccessing the welding system of FIG. 1 from a remote browser;

FIG. 4 is a screen shot illustrating a top level menu for accessing aremote operator interface and remote operator interface configuration,along with other functions, for use in the welding system of FIG. 1;

FIG. 5 is a screen shot illustrating a first screen for selecting aremote operator interface;

FIG. 6 is a screen shot illustrating a remote panel view as seen from aremote web browser;

FIG. 7 is a screen shot illustrating a first selection screen forestablishing a customized remote interface;

FIG. 8 is a screen shot illustrating the steps for establishing a custominterface;

FIG. 9 is a second screen shot illustrating the steps for establishing acustom interface;

FIG. 10 is a screen shot illustrating the customization process justprior to completion; and

FIG. 11 is a screen shot illustrating a customized interface aftercompletion.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the Figures and more particularly to FIG. 1, anexemplary welding system 10 for automatic and semi-automatic welding isshown. The welding system 10 includes a housing 11 containing a powersupply 12, a controller 16, and a communications system 30 forcommunicating with external components. These external components canbe, for example, the components of a welding cell, including flexible orhard automation components, such as a welding robot 21, a programmablelogic controller (PLC) 27, and fixtures 29. Alternatively, oradditionally, the external components can include one or more computeror computer network 31, provided in a factory automation system. Thecommunications system 30 can be connected to a series of networkedwelding systems 10, either directly or through one or more computer 31.Bi-directional communications between the welding system 10 and externaldevices are preferably provided through an embedded web server 33 incommunications system 30.

Referring now also to FIG. 2, a simplified block diagram of data storageand communication between the embedded web server 33 and remote clientweb browsers 37 provided on external devices such as those describedabove is shown. The screens associated with web server 33 areimplemented through a combination of static files 43 stored in memory onthe weld system 10, and dynamically generated files 41 created by webserver extensions 45 running on the web server 33. The static files 43include HTML web pages, cascading style sheet documents, image files andJavaScript source code documents. These files provide non-dynamiccontent for the web interface and a framework for dynamic content.Dynamic, variable data is provided via server extensions 45 executed onthe embedded microprocessor in the welder, and is stored in thedynamically generated files 41. This data can include, for example, aweld parameter library of variable data related to the control andperformance of weld system 10. The variable data in the weld parameterlibrary can include both input commands and output data, such as, forexample, weld command parameters for controlling the power supply 12 andwire feed system 20; digital control commands for activating anddeactivating weld system components; digital feedback or state dataindicating the state of weld system components; and weld parameterfeedback data, indicating the operational state of weld parameters. Anexemplary table illustrating the type of variable data that can bestored in a weld parameter library is provided in Table 1 below:

TABLE 1 Weld Command Parameters/Command Functions Volts Wire Feed SpeedFrequency Pulse width Rise time Fall time Torch Travel Speed Torch AngleWeld Component Control Commands/Control Functions Gas Wire Feed ForwardWire Feed Reverse Contactor Program select Weld Component StateParameters/Diagnostic Parameters Gas On Wire Feed Forward Wire FeedReverse Wire Stick Detect Touch sense Detect Volt Sense Detect CurrentDetect Contactor On Coolant On Weld Feedback Parameters/DisplayParameters Voltage Feedback Current Feedback Wire Feed Speed GasPressure Coolant Pressure Torch Travel Speed Torch Angle

Variable data, such as the data stored in the weld parameter library,can be combined with the static data 43, which can includepre-configured HTML pages, via JavaScript executed on the remote webbrowser 37. Alternatively, the variable data can be accessed from aremote client web browser 37 at a web-enabled remote robot 21, PLC 27,networked welder 10, computer 31 or other device. The variable dataprovided in the weld parameters library can then be retrieved through anHTML script or other program running at the web-enabled remote device37, and, as established by the HTML script, selective weld feedback andweld component state parameters can be viewed remotely. Additionally,the HTML script can selectively provide control of the weld controlcommand parameters and weld component controls from the remote device37.

High speed data exchange, as for, example, for communications withremote devices 37, is carried out through Javascript XHTTP requests, andthe appropriate server extensions respond to the requests by returningrequested data in JSON or XML format. Requests to the server 33 and allresponse from the server 33 are given an ordering number so that underhigh data loss conditions on the most recent data is used.

As discussed above, data can be retrieved from welding system 10 eitherby viewing web pages with variable data from the server extensionsincluded or by downloading generated log or configuration filesdirectly. Data is transmitted to the welding system 10 either via HTTPqueries or by uploading files. Although a web server 33 is describedhere, in addition to or as an alternative to a web server 33, thecommunications system 30 can include a serial communications link suchas DeviceNet, Profibus, RS-232 or other communications systems, orthrough a network communications device such as an Ethernet connection,or other wired or wireless communication devices.

Referring again to FIG. 1, the controller 16 can include one or moremicrocontroller, microprocessor, digital signal processor, or otherprogrammable controller, along with an internal or external memorycomponent 18, capable of storing weld configuration data, weldingprograms and procedures specified by the user. The controller 16 mayalso be connected to a user interface 32, which can be mounted in thehousing 11, or provided external to the housing 11 and welding system10, and can include a user display and input devices, such as keys,switches, joysticks, analog or digital potentiometers, or other devicesto provide information to and receive information from an operator oruser of the welding system 10.

Referring still to FIG. 1, the welding system 10 can also include aninput/output board (I/O board) 17, which provides connection points forexternal equipment to both provide input signals to the welding system10 and to receive discrete outputs from the welding system 10. Theinputs and outputs can include, among other indicators, welding processstate conditions and error conditions. Common welding process statecondition signals input and output through the I/O board 17 can include,for example, contactor on (weld on), gas valve on (purge), wire feedmotor foreword (jog), wire feed motor reverse (retract), weld programselection, and touch sense detect. Common error conditions can include,for example, voltage sense error, arc start error, wire stick errors,motor over current errors, coolant flow errors, or gas flow errors.Analog input and output signals, including voltage command and feedback,wire feed command and feedback, and current feedback can also beprovided on the I/O board 17. Welding state data, error data, feedbackand command data can also be transmitted to and from the welding system10 through communications system 30 discussed above, and by access to aweld parameter library as described above.

Referring still to FIG. 1, the welding system 10 is connected to aninput power supply line 15, typically a three phase supply, whichprovides power both for the control circuitry and for the power supply12. Voltage and current sensors (not shown) can be provided on the inputpower supply line to allow the power to power supply to be monitored,typically by controller 16. The welding power supply 12 is preferably aninverter power system, and can be a constant voltage power supply or aconstant voltage/constant current power supply, and preferably includespulsing capabilities, providing the ability to perform MIG(GMAW)welding, pulsed MIG (GMAW P) and flux-cored (FCAW) welding.

Referring still to FIG. 1, the controller 16 of welding system 10 isfurther connected to external welding components including a wire feedsystem 20, a gas valve 23, and, optionally, a coolant system 25. Thewire feed system 20 includes a motor 19 that drives wire through driverolls and a liner to a torch or gun 13 including a contact tip. The gasvalve 23 can be either an on/off valve, a metered valve controlled bycontroller 16, or can include a separate or integral flow meter.Similarly, when a coolant system is provided, the system can include anon/off or metered valve, and flow metering devices.

Optionally, the welding system 10 can also be connected to externalinput and output signals provided, for example, by components in awelding cell. The fixtures 29, for example, can include devices such asclamps for maintaining a work piece 14 in position during a weld, andpreferably also include sensing devices, such as devices for providing asignal to the controller 16 when associated clamps either open or close,and proximity sensors for sensing a position of the work piece 14 in thefixture 29 or a position of a welding torch approaching the work piece14. Additionally, a series of light emitting diodes, laser diodes, orother lighting elements can be provided in the fixture either toilluminate an area to be welded for the operator, or to provide anindicator to the operator. The indicator can, for example, indicatewhich in a series of welds is to be performed, providing a sequence forthe operator. Lighting and other visual aids can also be used toindicate when a welded part is complete. Audio-producing devices, suchas buzzers and horns, can also be associated with the fixture to providea signal to an operator or supervisor when a weld is complete, when anerror has occurred, or in various other situations. These devices can beconnected directly through the communications system 30, or through anexternal device such as the PLC 27, robot 21, a remote computer system,or other controller.

The welding system 10 can be used in various modes of operation,including both semi-automatic and automatic welding. Weld commandparameters can be stored as pre-programmed weld procedures in memory 18or provided to the weld system 10 through communications system 30, orselected through inputs to the I/O board 17. External devices, such as ahandheld gun or torch or other device with a trigger switch, a robotcontroller associated with robot 21, PLC 27, or a remote system anddisplay such as a externally connected PC, can provide a signal to thecontroller of the welding system 10 to start the weld. The weldparameter commands can be retrieved from memory 18, or be provided fromthe robot 21, PLC 27, or other external device through communicationssystem 30.

In operation, the controller 16 receives a trigger signal as describedabove and commands the power supply 12 to provide welding current andvoltage to start an arc at the work piece 14. Command levels forcontrolling the weld can be set and stored internally in memory 18, orcan be received from the external components, such as robot 21 and PLC27, or other controllers or computers as discussed above, either in theform of analog or digital control signals. Based on the input commands,the controller 16 also commands the wire feed system 20 to drive fillermetal from the motor 19 to a contact tip in torch 13, providing wire tothe weld at the work piece 14. The controller 16 also controls the gasvalve 23 to selectively provide shielding gas to the weld. Depending onthe type of gas valve used, the controller 16 can provide a simpleon/off signal, or control the level of flow from the valve 23.

During operation, the controller 16 receives feedback from a voltagesensor 26, a current sensor 28, and a wire feed speed sensor ortachometer 24, and can also optionally monitor gas flow through a gasflow sensor associated with the gas valve 23, and coolant flow incoolant system 25. The feedback data is used by the controller 16 tocontrol the power supply 12, wire feed system 20, and gas valve 23.Additional feedback data can also be provided from external components.This data can include, for example, travel speed of the torch, proximitysensor input data, clamp closure data, and other data. The controller 16can also monitor input voltage and current levels from input powerlines, and provide feedback data relate to these values, as well asaverage motor voltage and current values.

Referring again to FIG. 2 and now to FIG. 3, as described above, thewelding system 10 can include a remote operator interface serverextension 45 which allows weld parameter controls and commands forwelding system 10 to be provided from a web browser 37 at a web-enabledremote device such as a robot 21, PLC 27, a network of welding systems10, or remote computer system or server 31, and enables both control andmonitoring function from a remote location. This remote operatorinterface, moreover, can be customized to provide access to the control,command, diagnostic, and display data selected by a user, and thereforeto customize the display either for a specific function, or for aspecific user.

To access the remote control interface from a remote device, the useractivates the web browser 37 at the remote interface and accesses a webinterface login screen 40, constructed using data from the static files43 and dynamically generated source files 41 described with reference toFIG. 2, above, from the embedded web server 33. The interface loginscreen 40 prompts the user to select a user profile from a drop downmenu 42. As shown here, the access levels include an operator accesslevel, weld engineer access level, and a weld supervisor access level.

After the user profile is selected through the drop down box 42, theuser activates icon 44 to log in to the system, and is prompted toprovide identification (not shown). The identification can be a username and password, or an electronic or mechanical key, such as an RFIDtoken, or biometric authentication. For purposes of this description,the user is assumed to have chosen the “weld engineer” user profile andto have logged into the system. When logged in as either an operator orweld supervisor, however, the user would be provided with fewer ordifferent options for configuring the system than as described below.

Referring now to FIG. 4, after the password or other identification isaccepted, the user accesses a main interface menu 50. From the maininterface menu 50, the user can select between a number of differentlinks, including a remote operator interface control link 52, amonitoring link, a configuration link, a maintenance and update link,and a diagnostic link.

Referring now to FIG. 5, when the remote operator interface control link52 is selected, a display screen 53 is provided allowing the user toselect between a panel view 54 and a custom control interface 55.Referring now to FIG. 6, the panel view 54 provides a virtual paneldisplay which is configured in the same manner as a display provided,for example, on a user interface 32 associated with the welding system10. Here, fairly simple control and display options are provided. Theuser can select a weld program, select a process, wire type, and gastype, and can view and adjust voltage, arc adjust, wire speed, and amps.

Referring again to FIG. 5, when the user instead selects the customcontrol interface link 55, the user is provided with the option tocustomize a weld interface that can be operated from a web browser 37and that provides access to a selected number and type of functions. Byway of example here, the functions available for configuration on theremote display are categorized as display, control, diagnostic, andcommand functions. The “display functions” allow the user to monitor anddisplay current welding conditions by displaying welding parametervalues such as, for example, an actual voltage, current, and wire feedspeed during a weld, as well as a selected weld process or weld program.The user can also opt to display the command values provided to thewelding system 10, including a voltage/trim command, a wire feed speedcommand, and an arc adjustment or inductance command. “Commandfunctions” allow a user to establish a command value from a weldingprocess from a range of available values for controlling the powersupply 12 and wire feed system 20 of the welding system 10 from theremote interface, and again, specifically allow adjustment of avoltage/trim command, a wire speed command, and an arc adjustment orinductance command. The “command functions” can also allow for selectionof a weld program or a weld process from the interface from among anumber of available options. The “control functions” provide on/offcontrols at the welding system 10 from the remote interface and caninclude, for example, a trigger or start/stop weld function, and purge,jog, and retract controls, which selectively activate the gas valve 23and motor 19 in a forward or reverse direction.

“Diagnostic functions” allow the user to monitor parameters that can beindicative of weld or welding equipment malfunction as, for example, acurrent and voltage produced by the motor 19, and the level of the inputpower line connected to the welding system 10. Diagnostic data displayedat the remote interface can also include error data, such as a voltagesense error, an arc start error, wire stick errors, motor over currenterrors, coolant flow errors, or gas flow errors, and weld state data,such as contactor, jog, retract, remote program selection, standby andE-stop states. These errors are determined by the controller 16 in amanner known to those in the art.

Although specific functions are shown and described here, it will beapparent that these functions are by way of example only, and that auser-configured interface could include any number of display, control,command, diagnostic, and other functions. For example, from a remoteinterface, a user could also adjust timed parameters, such as pre-flow,post-flow, arc start delay, and burn back. Additionally, functionsuseful in setting up replacement equipment in a cell, such as a “robottype” and a “dry run” selection could also be configured on a remoteuser interface to enable activation of these functions. “Other”functions, such as an option of enabling a camera to visually monitor aweld in progress, can also be provided.

Referring now to FIG. 7, from the custom control interface screen 56,the user initially selects a number of functions to be displayed on thecustomized interface by activating up/down operational controls 60 and62. When satisfied with the selected number, the user selects a“continue” icon 64. By way of example here, twenty-five functions areavailable. However, it will be apparent that any number of functionscould be provided, and that the number of functions can be varied basedon the size of the display at the remote interface, the access level ofthe user, and many other variables. The access level, for example, canbe used to increase or decrease the number of functions available to auser. Thus, for example, an operator might be provided with sixavailable options, a supervisor with fifteen, and a weld engineer withtwenty-five.

When the save icon 64 is selected from screen 56, an interfaceconfiguration screen 68 is displayed, as shown in FIG. 8. Here, aninterface box 80, 82, 84, 86, 88, and 90, is provided on screen 68 foreach of the 6 functions selected above, and the user is presented with adrop down menu allowing the user to select between the differentcategories of functions described above. Specifically the user isprompted to associate each interface box on the remote screen with aselected display 70, control 76, diagnostic 74, or command 72 functioncategory. An “other” category, 72, or other functions, such as timingand set-up functions, can also be provided as described above. Thefunctionality of the interface box will vary depending on the selectedcategory. Thus, for example, a command function will provide both a datadisplay and a user interface that will allow a user to input a selectedcommand value, while a display interface box provides only the abilityto display a value, and a control interface only an an/off activationuser interface control.

Referring now to FIG. 9, after a category is selected for an interfacebox, the user is presented with another drop down menu, allowing theuser to identify a specific function for the interface box within theselected function category. As shown here, in the display category 70,the user can elect to display an actual voltage, an actual current, anactual wire speed, an actual weld program or a weld process in theselected box. The user can also elect to monitor a command value, suchas a voltage/trim command, wire feed command, and arc adjust/inductancecommand. In the command category 72, the user is prompted to selectbetween voltage/trim, wire speed, arc adjust, inductance, or a weldprocess or weld program, as described above, and can adjust the selectedvalues from the remote interface. Here, user inputs would be associatedwith the interface box to allow a user to adjust a value, or selectbetween a list of functions. As described above, these inputs could behardware inputs associated with an existing keyboard or keys, joysticks,etc., or provided as touch screen or mouse-driven icons. Various methodsof providing inputs will be apparent to those of skill in the art. Inalternate embodiments of the invention, the user could also select aninput device to associate with selected input boxes from, for example, amenu.

Referring now to FIG. 10 when the diagnostic category 74 is selected,the user can select to display a motor voltage or a motor current, andto monitor a line power in the facility in which the welding system 10is operating. The motor parameters can be monitored, for example, toidentify and diagnose problems in the wire feed system. Input linepower, similarly, can be monitored to determine both the input level ofthe power, and fluctuations that might cause problems in the output ofthe power system 12. As described above, the diagnostic category 76 canalso allow a user to display welding state data (contractor, jog,restart, pause) and error data (wire stick, arc start error, etc.)

Referring still to FIG. 10, in the control category 76, the user canselect a jog, wire retract, purge control, and a program start/stopcontrol. As each of these functions require a user to provide an input,for the control category 76 the interface boxes are associated with aninput device which can be, for example, an icon on a touch screen, a keydedicated from a keyboard, a mouse activated icon, or various otherinput devices, as will be apparent to those of skill in the art.

After each of the selected boxes is associated with a specific function,the user selectively activates the build icon 83. When the build icon 83is activated, the screen configuration data is saved in a JavaScriptwhich can be stored either as a URL for the page, in a cookie stored onthe client browser 37, or in a database stored in memory 18 associatedwith the web browser 33 in the welding system 10. Alternatively, ifadditional functions are desired, the user can select the change numbericon 85 to add additional functions to the display.

Referring now to FIG. 11, after the “build” function is completed, theselected command, diagnostic, control and other functions are allprovided on the screen 86. In the example shown here, the user can viewthe actual voltage and current program, monitor the current program anderror status, and select a program.

The present invention therefore provides a significant advantage overthe prior art by providing a highly flexible display system. Byselecting the types of data to be displayed on the screen and theavailable controls, specific functions can be customized, and variouslevels of control can be provided. Thus, for example, customizeddisplays could be provided for operators at varying training levels. Foran inexperienced operator, for example, the controls could be limited toa weld program selection and a start/stop control, and all othercontrols could be disallowed. For a more sophisticated operator or asupervisor, the display could provide access to control a voltage andwire feed command level, and provide monitoring functions includingactual voltage and wire feed speeds.

A remote display screen could also be customized to allow a supervisoror other personnel to monitor a weld from a remote location. Here, forexample, display parameters such as voltage and wire feed speed feedbackcould be monitored, in conjunction with error data. Additionally, totroubleshoot problems with the welding equipment, a user could establishcustomized screens providing specific sets of display and controlfunctions. Thus, for example, to troubleshoot a wire feed problem, auser could elect to control a jog and a retract function, to monitorwire feed speed command, actual wire feed speed feedback, motor voltageand current, and monitor a wire feed relay.

Additionally, screens could be customized to simplify equipmentreplacement. Here, for example, a screen could be provided with a robottype selection, a dry run control, and purge, jog and retract switches.These controls would allow a user to associate the connected weldingsystem 10 with an appropriate robot 21, and to verify operation of thegas valve 23 and motor 19 when setting up a weld cell. As these variousremote operator interfaces are constructed, they can be bookmarked orsaved as a favorite, and then recalled when needed.

Although, as described above, in one aspect of the invention, the useraccesses pre-configured web screens 40, 50, 53 54, 55, and 68 from aremote web browser 37 to provide a pre-configured display, a user canalso configure remote control and command screens at remote web browsers37 through customized html scripts or other programs running on theremote web browser. These programs can, for example, access thefunctions provided in a weld parameter library, discussed above withreference to FIG. 2, and provide controls for commanding the powersupply 12, wire feed system 20, gas valve 23, coolant 25, or externallyconnected devices such as the robot 21, PLC 27, or other hard automationcomponents. In addition, through access to the weld parameter library,html scripts at the web browser 37 can access weld feedback and weldstate parameter data and display this data. Alternatively, a user couldmonitor the data, or combine feedback and state parameters, to establishself-configured error conditions or alarm conditions. As discussedabove, through access to available weld control and feedback parameters,the user can configure specific screens and provide specific access forvarious levels of users.

Referring again to FIG. 4, when using the pre-configured screensprovided through web server 33, various other functions are available tothe weld engineer from the main menu 50, as discussed above, including amonitoring link, configuration link, and a diagnostic link. When themonitoring link is selected, the user can, for example, view weld dataand summaries, access monitoring logs, and download weld wave form data.

From the configuration link, the user can edit welder configuration dataand save this data to a PC or upload the data from a PC. Configurationdata accessed from this screen can include, for example, provide accessto activate or deactivate a number of different errors including avoltage sense error, an arc start error, arc run time errors, wire stickerrors, motor over current errors, coolant flow errors, or gas flowerrors. Additionally, the configuration screen can provide locks toallow a supervisor to either selectively or globally lock access to weldprograms or functions.

The maintenance link can provide a system back up and recovery options,and software update options. In the diagnostic screen the user can viewand clear an error log, view the states of various inputs and outputsincluding, for example, the contactor, jog, retract, remote programselection, e-stop, wire feed and voltage outputs including currentdetect, standby, error modes, wire stuck errors, coolant errors, touchsense errors, voltage feedback and current feedback can be viewed. Fromthis screen the user can also control the contactor, the gas valve, andthe motor in both the forward and reverse direction in order to verifythe operation of the contactor and any purge functions and jogfunctions. From the diagnostic screen, the user can also downloadcurrent status and debugging information, and email the data to aservice center for assistance with troubleshooting.

It should be understood that the methods and apparatuses described aboveare only exemplary and do not limit the scope of the invention, and thatvarious modifications could be made by those skilled in the art thatwould fall under the scope of the invention. For example, whilefunctions are provided in various category types above, and theselection process is described as including a category selection and afunction selection. it will be apparent that all available functionscould be displayed to a user at one time, and the user could selectbetween the displayed functions rather than selecting by functioncategory as described above. Alternatively, a function look-up displaycould be provided, or the various functions could be provided on a menu.

Furthermore, while a specific set of screens is described above, it willbe apparent that these screens are provided by way of example only, andthat the described functions could be implemented in a number ofdifferent ways, and in various configurations. Additionally, althoughspecific data types are described with reference to each of the screensdescribed above, it will be apparent that the data could be configuredin any number of ways.

Furthermore, although the embedded web server is shown above as providedinternal to a housing of the welding power supply, it will be apparentthat the server could be provided in an external housing, or provided ina housing elsewhere within the welding system.

To apprise the public of the scope of this invention, the followingclaims are made:

What is claimed is:
 1. A method for providing a customized remoteinterface for a welding power source having an embedded web server, themethod comprising the following steps: communicatively coupling anembedded web server to a controller of the welding power source;programming the embedded web server to provide selective access toexecutable weld functions from an interface at a remote web browser, theweld functions selectively providing at least one of a display functionfor displaying selected weld parameters and feedback, a control functionfor controlling welding power source functions, and a command functionfor providing output commands to the welding system; prompting a user toselect a plurality of the executable weld functions to customize aninterface to display weld feedback, control welding system on/offfunctions and command weld output at the power source and wire feederfrom the remote browser; building a remote interface to include theselected executable weld functions; and selectively storing thecustomized remote interface for recall from at least one of the remotebrowser or another browser.
 2. The method as recited in claim 1, whereinthe step of programming the embedded web server comprises dynamicallygenerating pages created by web server extensions running on theembedded web server.
 3. The method as recited in claim 1, wherein thestep of programming the embedded web server comprises storing staticdata accessible to the dynamically generated pages in a memory componentin the welding power source.
 4. The method as recited in claim 3,wherein the static data comprises at least one of an HTML web page, acascading style sheet document, an image file and a JavaScript sourcecode document.
 5. The method as recited in claim 1, wherein the step ofselectively choosing a display function comprises enabling a user toselect between and specify display of at least one of an actual voltage,an actual current, and an actual wire speed feedback parameter forinclusion on the interface at the remote web browser, and accessingreal-time feedback data for these functions from the welding powersource.
 6. The method as recited in claim 1, wherein the step ofselectively choosing a display function comprises enabling a user toselect between and specify display of a selected weld program, and aweld process type that is in use at the welding power source.
 7. Themethod as recited in claim 1, wherein the step of selectively choosingthe control function comprises providing access to an operator at theremote browser to selectively activate an on/off function correspondingto the welding power source and the wire feed system, the controlfunction providing at least one of a trigger weld function, a purge, ajog, and a retract control.
 8. The method as recited in claim 1, whereinthe step of selectively choosing the command function comprises enablingan operator at the remote browser to selectively display and adjust atleast one of a voltage/trim command, a wire speed command, and an arcadjustment/inductance command that provide an output command level forat least one of the welding power source.
 9. The method as recited inclaim 1, wherein the step of building comprises the step of accessing alibrary of control functions for displaying and controlling weldparameters in the welding power source, to provide the user access tobuild a customized operator interface at the remote client browser formonitoring and controlling the power supply.